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By S. A. TAYLOR

THERE is probably no other mineral industry of which the public has as much information and misinformation as it has of the coal industry. Unfortunately, however, the general public's knowledge of the coal industry, outside of the particular kind of coal it is accustomed to, by reason of use, is largely made up of information received from newspaper and popular magazine articles, in which the mine workers are depicted as overworked and mistreated men, and the coal operators as "coal barons." Those who have any specific knowledge of exact conditions in the coal industry know how unjust and un- fair such an opinion of the coal industry is, not only to the miner but to the operator as well. Many reporters and writers of magazine articles are misled by statements regarding the condition of the miners that are exaggerated and not founded on facts and, if an investigation of the conditions of the miner's work, his habitation and surroundings were fairly made, it would at least compel more truthful statements by those who write for public reading. That such an investigation would not reveal anything that was wrong, or anything to be censured or cured, no one, I think, would maintain, but I do think that any fair investigation of the facts would show that conditions in and around the newer and later-developed coal mines and communities would compare favorably with those of manufacturing districts, and that where the mines and com- munities are old and not very attractive places to work, or live in, they carry with them other considerations, compensating for these conditions, and cannot be remedied by reason of a lack of sufficient coal to warrant economically any costly changes.

Jan 1, 1926

By J. F. Labuz

Fracture tests were conducted on subsize specimens of Charcoal granite to demonstrate that the extent of the nonlinear region at the crack tip can be significant. The model of the fracture process considers an effective crack length as a traction free portion plus a process zone where closing stresses act; this zone is identified by microcracking and interlocking. A singularity is allowed at the effective crack tip. The effective stress intensity factor is the superposition of the stress intensities due to the effective crack and the process zone. By assuming that the closing stress is a linear function, it is shown that a process zone length of approximately one-third the effective crack is needed to match the compliance-determined crack length.

Jan 1, 1984

By W. D. Robertson, Raymond C. Boettner

A study was made of the change in density during the first (transient) and second (linear) stages of the creep curve of polycrystalline copper as a function of 1) stress, 2) temperature, 3) plastic strain, 4) impurity and atmosphere effects, and 5) structure, including single crystals. Voids were not observed in single crystals strained 15 pct at 500°C, or in a polycrystal-line aggregate produced by recrystallizing a single crystal, within the limit of sensitivity, Ae/e = 1 x 10-4. It appears that voids are heterogeneously nucleated at grain boundaries by an insoluble phase, or phases, which can be removed by directional solidification. The principal controlling mechanism of void growth appears to be condensation of vacancies at grain boundaries. Vacancies are transported to a boundary and condense as a consequence of the tensile stress component across the boundary, which depends on the orientation and configuration of the boundary plane and on boundary shear across ledges and other irregularities. The ultimate source of vacancies is the free surface and diffusional transport is by way of the boundary plane. PREVIOUS investigations have dealt with the nucle-ation of voids at grain boundaries under creep condition~'-~ and with the connection between grain boundary voids and subsequent brittle fracture.5-7 Growth of voids during the creep process, particularly in the transient and linear stages of creep, has not been studied with the same intensity. Therefore, it seems pertinent to investigate the process of void growth with respect to the related creep curve, and the morphology of growing voids with respect to the structure.

Jan 1, 1962

By K. A. Slagle

Hydraulic analysis of the wellbore has become increasingly inzportant for designing cementing operations and selecting equipment, materials and techniques to complenzent modern well-c-ompletion practices. Non-Newtonian fluid technology has advanced beyond the point where former empirical methods of analysis adequately define the hydraulic system and fluid properties. In view of these factors, this paper describes a series of rheological calculations which have been found practical, through field usage, for assistance in selecting a cementing program. A relatively simple laboratory method using standard viscometric equipment is suggested for determination of the rheological properties of slurries, and clrrta are presented on some of the more common cementitrg conzposition.A. A criterion for divergence from laminar-flow characteristics has been proposed. Usefulness of the calculations is indicated by examples of cementing operations where they have been used. INTRODUCTION With the changing aspects of well-completion practices during the past few years, it has been increasingly important to have a relatively simple method of analyzing the flow conditions existing in the well during cementing operations. This is particularly true in view of the improved economics toward which most of the changes have been directed. Rheological characteristics of slurries used for cementing should be a major consideration in the trend toward smaller casing sizes, either single or multiple strings. Receiving increased attention is the practice advocated in 1948 by Howard and Clark' of attaining turbulent flow with the fluids circulated during a primary cementing operation. While there may still be a difference of opinion concerning this technique, most available information indicates that superior primary-cementing results are generally obtained when high displacement rates are employed. Fluid properties of the slurry to be used must be available, as well as calculation methods, to determine what flow rates should be attained and the probable consequences in terms of frictional pressure and horsepower utilization. It would certainly be inappropriate to attempt high displacement velocities if sufficient pressure might be developed to create lost circulation. Since cementing slurries are non-Newtonian fluids, it is not possible to define their rheological or fluid properties by the single factor of viscosity and then make calculations for the quantities just described. Because the shear stress-shear rate ratio is not constant: it becomes necessary to establish at least two parameters for adequate fluid-flow calculations. It is not the purpose of this paper to delve into the mathematical development of non-Newtonian technology, nor to discuss the arbitrary classification system under which a single fluid may resemble two or three different classes depending upon experimental conditions. Rather, the intention is to present a useful series of calculations based on a concept applicable to both Newtonian fluids and to the preponderance of non-Newtonian fluids encountered in the oil-producing industry. Development of this approach was begun some 32 years ago,' and has most recently been brought to fruition by Metzner and his co-workers at the U. of Deleware. Some non-Newtonian fluids encountered in the petroleum industry, other than cementing slurries, have also had the benefit of this method of analysis."' The two parameters required to define the fluid are usually denoted by the symbols n' and K' and, for the purposes of this discussion, are called "flow behavior index" and "consistency index", respectively. These two slurry properties permit calculation of the Reynolds' number and the "critical" velocity, or the velocity at which departure from laminar flow begins. EXPERIMENTAL DETERMINATIONS The two principal instruments used for rheological studies are the pipeline (capillary-tube) viscometer and the rotational viscometer. When conveniently possible, a capillary-tube viscometer (where the pressure drop and flow rate of the material can be measured) is the better method for rigorous determination of the flow behavior index and consistency index for non-Newtonian fluids. With pressure-drop data at various flow rates, it is then possible to prepare a logarithmic plot of shear rate as the abscissa-shear stress as the ordinate. For fluids which do not exhibit time-dependency, these data will usually produce a straight line. The flow behavior index n' represents the slope of this line, while the consistency index K' becomes the intercept of this line at unity shear rate in accordance with the mathematical derivations associated with this concept of rheology. Due to the difficulties anticipated in maintaining a uniform, pumpable cement slurry for the time interval required to obtain measurements from the pipe viscometer, the n' and K' data reported herein were obtained using a direct-indicating rotational viscometer (Fig. 2). The

By G. D. Oxx, L. F. Coffin

The concept of using a phase that is liquid at service temperatures as a component of coatings for refractory metals has been described. The liquid, an alloy of gold and silicon, is retained on a molybdemum surface by a capillary system made of molybdenum disilicide. The coating has the advantage of good thermal shock and has a self-henling chracteristic. In order for highly stressed structures to exceed a service temperature of 2000°F, it has become apparent that a development that does not depend on the traditional iron, cobalt, or nickel-base alloy is needed. Alloys of the refractory metals, i.e., molybdenum, tungsten, tantalum. niobium (colum-bium), and rhenium are potentially useful at extremely high temperatures that more conventional alloys would never be expected to achieve. A new alloy of molybdenum has become available that has a 100-hr rupture strength of 35,000 psi at 2200°F.1 As a result of this work, it may be assumed that a material with adequate mechanical properties at 2200?F is now available. Unfortunately, this alloy and all other known alloys of the refractory metals suffer from not being; serviceable in an oxidizing atmosphere for a very long time. In order to permit general use of refractory metals at high temperatures, it is necessary to prevent destructive oxidation by appropriate alloying or by protective coatings. The liquid phase coating reported here is representative of a concept for the protection of metals that permits higher service temperatures and introduces a new group of materials for selection as coatings. Coating Requirements—Service conditions that represent potential applications for refractory metals vary considerably: however, it is possible to consider two conditions that are usually present. The refractory metal1 component must be heated to the service temperature at least once and usually frequently. When a solid coating is used, usually the coating and basis metal do not have the same coefficient of expansion. This difference causes thermal stress in the coating that is aggravated by rapid heating and cooling and eventually causes coating failure. The second consideration is the probability that there will be damage to the coating by some environmental condition. In jet engines, for example, it is expected that large particles, stones, metal parts, and so forth, will strike a bucket at high speed and cut a hole in the coating. In addition to the above considerations, the coating must also have other fundamental properties. Obviously, it must be oxidation resistant. In addi- tion, it must prevent permeation of oxygen and subsequent oxidation of the basis metal at the interface. Also, diffusion of the basis metal to the outside surface and subsequent oxidation there must be prevented. Finally, the coating must not react with the basis metal to form a weak bond at the interface. It should be noted that the coating need not support a load: it must only remain intact. Liquid Phase Coating Design Factors—In the use of a liquid as a principal coating constituent, it would be expected that the two service conditions mentioned above would be satisfied. A liquid would flow under the influence of the thermal strain developed by coating-basis metal expansion mismatch such that failure from this source would not be expected to occur. It is also probable that the ability of a liquid to flow would provide a self-healing effect. Thus, damage caused by particles in the atmosphere would be repaired. A third advantage is evident in that vapor pressure rather than melting point limits the service temperature. This latter advantage permits use of low melting but oxidation resistant metals such as gold or copper that would be quite useless if the solid state was required. A low viscosity liquid alone. however, is a totally unsuitable coating because it will simply flow off a component, particularly under the influence of a high acceleration field. A method of preventing liquid loss must be devised. In this case, it is desired that the liquid have a low viscosity so that it may easily flow into flaws; thus, raising the viscosity is not a satisfactory solution. One other inherent difficulty is caused by the high mobility of atoms in the liquid state as compared to the solid state. Because of this mobility, it would be expected that gases would diffuse more rapidly through a liquid. It is also probable that the solubility of oxygen in the liquid would be comparatively high. These factors would tend toward rapid permeation of oxygen and oxidation of the substrate. It is most reasonable that this problem could be solved by incorporating a solid phase, which is impermeable to gases, as a component of the coating. To overcome the tendency of a liquid to flow easily, it is possible to use surface tension to advantage. If the surface were made up of a large number of capillary tubes of sufficiently small diameter, then surface tension would hold the liquid even against the acceleration of a centrifugal field.

Jan 1, 1961

By L. W. McKeehan

IT is no longer necessary, if it ever was, for your annual lecturer to apologize for including in his remarks frequent references to the arrange-ment of metal atoms in crystals and for basing his arguments that metals behave as they do upon their crystal structure. Neither will any objec-tion be raised because the large metallic crystals of which we will speak are hard to prepare and of negligible commercial interest. The particular set of physical properties we propose to discuss-ferromagnetic proper-ties-may require more justification. Very few in this audience are primarily, or even remotely, interested in the ferromagnetic behavior of the metals they handle. By no means all of you ever deal, by choice or by necessity, with metals which display any ferromagnetism at all, and even those who study or control ferrous metallurgy must usually depend upon electrical engineers for assistance in ferromagnetic applications. My excuse for talking about such an obvious specialty is, like all Gaul, divided into three parts. In the first place, the members of the com-mittee who select the annual lecturer must wish the speaker to confine himself to matters he has at least thought about before he prepares his speech. In the second place, the study of ferromagnetism in crystals has, as you will soon realize, suffered in the not-too-distant past from inade-quate metallurgy. Further progress probably depends upon proper use being made of the skill and knowledge of some members of the Institute of Metals Division who have not, before today, been asked to think about the problems presented here. Finally, there is at least a sporting chance that the ferromagnetic properties of a few metal crystals will give some insight into the more generally interesting properties which they share with nonferromagnetic metal crystals.

Jan 1, 1934

By K. E. Brown, F. W. Jessen

It is deemed feasible to store atomic reactor fuel wastes in salt dome cavities when the differential pressure acting on the cavity does not exceed 3,000 psi and the temperature is less than 400°F. Tests at pressure increments of 1,000 psi were conducted on a 2-in, cylindrical cavity contained in a 6-in. long X 6-in. diameter salt core. The cavity exhibited stability under pressures up to 3,000 psi and temperatures to 300°F. At temperature ranges of 100 to 400°F and with pressures of 5,000 psi and above continuous deformation of the cavity resulted. Initial movement of the salt was observed at all pressares. This was evidenced by vertical deformation and cavity size reduction. INTRODUCTION The development of storage techniques for safe disposal of atomic reactor fuel wastes is a goal of the Atomic Energy Commission. Salt domes have been used successfully for storage of liquefied petroleum gases and hence should prove to be suitable for liquid waste products of atomic reactors. The purpose of the following work is to evaluate the practicability of utilizing salt dome cavities for such wastes and to de-termine particularly the effect of pressure and temperature on a salt cavity. This work represents a part of a comprehensive study covering the over-all problem of storing re- actor fuel wastes in salt domes and/ or salt beds. The problem of accurately determining the stresses which exist in rocks in the earth's crust is indeed a complex one. Theoretical studies have differed widely in many of the basic assumptions about the physical properties of the rock itself. Some solutions of problems in underground stress analysis assume that rock is elastic, homogeneous and isotropic in character; others assume that rock possesses plastic, viscous, elasticovis-cous properties, or a combination thereof. Experimental evidence has shown that salt possesses plastic, viscous and elasticoviscous properties.' Recent work has shown that salt becomes more plastic with temperature.' APPARATUS AND PROCEDURE For experimental study a cylindrical cavity was chosen for analysis since it provided maximum volume per unit of depth with constant diameter. This particular cavity shape, allowing for irregularities, can be easily leached out of salt domes in field operations. For the purpose of approaching underground storage conditions as nearly as possible, the following factors were considered: (1) control of pressure and temperatures, (2) measurements of temperature gradients throughout salt mass, and (3) measurement of structural stability of salt cavities. In order to obtain triaxial pressure on the salt cavity without resorting to the application of fluid pressure directly on the salt mass, a system was designed whereby the same effect could be produced through axial loading only. By cutting a core to close dimensions to fit a steel test cylinder and applying axial pressure, a lateral pressure was obtained. This equipment is shown in Figs 1 and 2. A steel cylinder was made from

By Larry Dale

An approach for predicting the development of mineral resources on public lands has been developed as an aid to resource agencies. It consists of new techniques for evaluating the economic potential of the resource, the uncertainty about mine cost estimates, and the uncertainty about the occurrance of mineral deposits. New mineral sup- plies from inferred and hypothetical resources can be predicted by using these techniques. A case study illustrates their application in predicting development of copper resources in western Montana.

Jan 1, 1982

By R. Maddin, C. H. Mathewson, W. R. Hibbard

Recent publicationsl.2 establishing the presence of cross-slip in strained metallic single crystals oriented wholly within the area of single slip as predicted from the generalizations of Taylor and Elam3 described these markings as they appeared during the initial stages of the deformation process. At that time, the plane having a common glide direction with the primary slipping plane was reported as the cross-slip plane although the specific direction was not confirmed. Consequently, in continuation of the research, it seemed advisable to investigate the micro-graphic appearance of cross-slip together with the Laue back-reflection X ray analysis and stress-strain data during the later stages of the deformation process. Accordingly, a single crystal of brass (72.75 pct Cu, 0.01 pct Fe, 0.01 pct Pb, 27.23 pct Zn) was polished mechanically and repolished electrolytically after the manner described in the earlier paper.' Three pairs of flat surfaces, parallel to the specimen axis, and (1) perpendicular to the plane containing the pole of the primary glide plane and the specimen axis, (2) perpendicular to the plane containing the pole of the cross-slip plane and the specimen axis, and (3) perpendicular to the plane containing the slip direction and the specimen axis, were polished mechanically and repolished electrolytically, resulting in a final minimum gauge diameter of 0.4864 in. in a gauge length of 3.36 in. The specimen was elongated in tension and load-extension readings were taken following the method described in the initial investigation.' Observed reorientations were obtained from a series of Laue back-reflection photograms at the center and ends of the gauge length and at various positions around the circumference of the specimen. These were interpreted after the manner of A. B. Greninger.4 Cross-slip (Fig 1 and 2) was found with the first appearance of the primary slip clusters and usually joined members of these clusters. In addition, a third set of entirely different markings (Fig 3) could be noted. The displacement of this third set by the primary slip lines was measured as 8300 at. diam (3.04 microns). Since the specimen was carefully observed at high magnifications before any deformation and no markings of any type could be noted, it would appear that this third set was formed during the deformation process prior to the initiation of classical primary slip. Additional extensions produced no unusual change in the appearance of either cross-slip or the third set of markings. The number of lines increased with increasing elongation and appeared, generally, in areas where earlier markings were present. The continuity of the clusters of cross-slip lines in Fig 4, 5 and 6 illustrates that they are neither noticeably displaced by nor do they displace the primary lines at this stage. In Fig 7, cross-slip appears in a long narrow localized band approximately 45 degrees from the stress axis. This somewhat resembles a twin band except for the lack of a sharp boundary. After a shear of 0.257, suffcient additional glide occurred on the cross-slip plane to displace the primary slip lines (Fig 8). Generally, where a large number of cross-slip lines could be observed in an area on one flat surface, few cross-slip lines appeared on the diametrically opposite position on the parallel flat (Fig 9). These, of course, were not matched observations on the same glide ellipses. It was extremely difficult to make such comparisons. The third set of markings (Fig 10) was extensively displaced by glide on the primary slip planes. A plot of the width of primary slip clusters versus their displacement of the third set of lines is shown in Fig 11. The slope and the linearity of the plot suggest that each primary glide plane slips to a constant maximum value of shear before further slip is transferred to another plane. A shear value of 0.28 was determined in this case. Heidenreich5 has presented a similar schematic representation of glide for aluminum. After the specimen had attained an elongation of 51.8 pct, corresponding to a shear of 0.973, cross-slip appeared very prominently in certain areas as shown in Fig 12, yet at diametrically opposite positions very little cross-slip could be noted, Fig 13. Classical conjugate slip was found at this advanced stage in the deformation, Fig 14, which corresponds to the axial location shown at 12 in Fig 15. It should be noted that cross-slip occurs within the conjugate slip clusters and on the same plane as the cross-slip associated with the closely spaced primary lines which constitute a background in less distinct focus. The third set of markings noted at all stages in the deformation of the

Jan 1, 1950

By J. J. Gilman, T. A. Read

FOLLOWING the deformation 01 zinc monocrys-tals, sharply bent basal planes are observed near several types of inhomogeneities. Three of these in-homogeneities have characteristics which are quite regular so that they can be studied and analyzed. These are compressive kink bands, "deformation bands," and the inhomogeneities near end restraints. The present paper describes experiments in which "deformation bands" were artificially produced, and bend plane phenomena are discussed in terms of dislocation theory. Also, two new bend plane phenomena are described. The importance of bend plane phenomena in the deformation of crystals is not widely recognized. Many phenomena may be explained in a manner similar to the discussion in this paper. Jillson1 has pointed out that the "punching effect" in zinc is a bend plane phenomenon and is not caused by prismatic slip.' Bowles3 has suggested that they may be involved in diffusionless phase changes. Cahn4 has discussed the role of bend plane formation in the polygonization of zinc. Experimental Work Tensile Kink Bands: Because of the geometrical similarity between "deformation bands" and "kink bands" (compare Fig. 1 of this paper with Fig. 1 of the paper by Hess and Barrett"), the band shown in Fig. 1 of this paper will be called a "tensile kink band," and that shown by Hess and Barrett will be called a "compressive kink band." It is felt that the term "deformation band" should be reserved for banded structures in polycrystalline materials such as iron." Tensile kink bands seem to form spontaneously in aluminum crystals deformed by tensile loading.7-10 In zinc and cadmium crystals they do not form in good, carefully loaded specimens.'." However, tensile kink bands can be produced artificially in zinc crystals. The present authors did this by scratching one of the flat surfaces of triangular crystals transversely with a sharp needle. Natural tensile kink bands caused by inhomogeneities sometimes appeared in deformed crystals which were identical in appearance with the artificially produced ones. Zinc monocrystals were grown by the Bridgman method in graphite molds. Chemically pure zinc (99.999+ pct Zn) was used and the molds were sealed inside evacuated pyrex tubes during growth. The crystal cross sections were equilateral triangles with a typical base of 0.210 in. The artificial kink band shown in Fig. 1 is typical of tensile kink bands in zinc. The band lies between two bend planes which run from upper right to lower left and is inclined oppositely to the slip bands which are sharply bent at the two bend planes. The general form of the artificial tensile kink bands was independent of the scratch depth (1 to 5 mils deep) and also independent of which side was scratched. These variables did cause variations, however. Deep scratches produced more localized kink bands than light scratches. Also, if the angle between the slip plane traces and a transverse scratch varied appreciably among the three sides, then localization of the resulting kink bands also varied. Furthermore, if the slip direction lay nearly parallel to the scratched side, the band was more developed near the scratched side than at the opposite edge. Scratches produced tensile kink bands for crystal orientations from xo = 15" to x, = 75". Fig. 2 shows a scratched crystal after deformation. One triangular side lies in the plane of the photograph. The right hand tensile kink band was produced by a transverse scratch on the upper right side. The next two kink bands were the result of scratches on the front surface. The kink band at the left was caused by a scratch on the lower back side. All four bands have the same general form. A longitudinal scratch was also made on the crystal shown in Fig. 2 to determine the effect of a scratch on the critical shear stress. The critical shear stress of the scratched region was 33.9 g per sq mm compared to 24.4 g per sq mm for the un-scratched region above it. Fig. 3 shows Laue patterns of the crystal shown in Fig. 2. Fig. 3a shows the pattern of the undeformed crystal. The orientation was x, = 21°, A, = 31". After deformation, Fig. 3b was made of the homogeneously deformed portion of the crystal. The spots are compact but split into two halves. This region was elongated 45 pct and its orientation was x = 14", X = 20"; the sine law predicts x = 14", A = 20.5". Fig. 3c was taken near the center of the middle tensile kink band of Fig. 2. The pattern shows a range of orientations and polygonization in this region. The spread in orientation was due to the fact that the basal planes were curved (see Fig. 1) rather than flat as in the ideal case. Some may also have been the result of elastic distortions and "local curvatures." The orientation range was x = 23" to 32", A = 30" to 42". It is apparent from Fig. 3 that the material inside and outside the kink band rotated in opposite directions with respect to the tension axis during deformation. The orientation calculated from the ideal configuration of Fig. 9,

Jan 1, 1954

By Clyde Williams

IN this war as in no former one, the use of metals has been the major factor governing success. For building new plants, new transport facilities whether by land, sea, or air, for our mechanized army, and for nearly all weapons, iron and steel has provided the basic material. Being the world leader in iron and steel production in peacetime, we soon adapted plants to production for war. Starting with a production of 66,000,000 tons of steel ingots in 1940 from a rated capacity of 80,000,000 tons which only could be reached by straining every productive device available, our industry expanded to 86,000,000 tons in 1942, and ultimately to 96,000,000 tons. To do so required expansion of every unit operation including mining, rail and water transportation, blast-furnace and steelmaking facilities, and rolling mills. New plants not only had to be built in record time but more output for each operation was essential. This performance required skillful operation and engineering techniques and also a better understanding of the physics and chemistry underlying such complex operations as the working of a big blast furnace. A vastly increased pig iron production made possible the great output of steel by an industry that had depended on scrap for its basic raw material even though sufficient scrap was unavailable. This was done by conversion of pig iron in the Bessemer either into steel or into a low-carbon product that was subsequently used in place of scrap in the open¬hearth steel furnace. Furthermore, by duplexing from the open-hearth to the electric furnace, and the construction of many new electric furnaces, our output of electric-furnace alloy steel was greatly increased. Moreover, techniques were developed by which alloy steel could be made in the open hearth with the result that our production of alloy steel reached the fantastic figure of 15,000,000 tons a year.

Jan 1, 1945

By M. V. Lowry

This paper outlines the economic considerations that led to the recent installation of a thickener at St. Joseph LeadCo.'s Balmat, N.Y. mill. To incorporate storage of concentrates, they decided upon a single, unusually deep tank to be used for both storage and thickening. The abnormally high rake lift required was achieved by the novel feature of having the entire drive platform raise and lower. Initial operating problems are described along with the satisfactory solutions. Total costs for concentrate handling before and after installation of the storage thickeners are compared. In Northern New York State, the St. Joseph Lead Co. conducts a 2100 tpd zinc mining and milling operation at its Balmat Plant. Conventional crushing, grinding, and flotation is used to produce a zinc concentrate. For 32 years, from 1930 through 1962, the plant operated with the concentrates going directly from flotation to the filtering, drying, and loading facilities. All of the concentrate handling equipment, therefore, had to operate 24 hrs per day. It also had to accommodate wide fluctuations in tonnage, due to variations in the grade of ore. Many problems were thereby encountered in filtering and drying, but it was never concluded that the cost could be justified for installing a conventional, large diameter thickener. Finally, in 1963, they installed an unconventional thickener that is unusual in several respects. The tank depth is 16 ft instead of the normal 8 ft. The rakes are raised and lowered by having the main drive gear located on a movable platform. Automatic controls are programmed to raise the drive platform and rakes during one shift of storage. During the next two shifts of withdrawal, the controls are programmed to lower the drive platform and rakes. After three years of operating this unique storage-thickener, the conclusion is that a correct choice was made from several alternative schemes for storing concentrates. The various considerations involved in the final selection will here be analyzed, and the design features and installation details will be de- scribed. Operating problems and modifications made to the equipment will next be considered, and finally the effects upon filtering, drying, and loading will be reported. SELECTION CONSIDERATIONS Even without a thickener, concentrate handling had become reasonably efficient at the Balmat Mill by the year 1962. A tonnage that varied between 6 and 25 tph was being handled fairly satisfactorily. The filter cake moisture of 8%% seemed quite respectable, except that two large filters were usually in service. Three filters often had to be operated in order to prevent excessive filter overflow with consequent loss of values. This situation occurred when zinc concentrates from flotation exceeded 20 tph and when filter cloth blinding developed. Over the years, numerous small improvements had been effected, such as: selection of a filter cloth with better flow characteristics; addition of flocculant to the filter feed; and, in 1953, the smallest of three drum filters was replaced by a five disc, 8' 10" diam filter with a bottom agitator and snap blow. As another example of fairly efficient operation, the oil-fired dryer was doing a seemingly satisfactory job of further reducing the moisture content to an average of 3%. However, there were often considerable dust losses when the tonnage suddenly dropped off to 6 tph. At high tonnage rates, the resulting high moistures of 4% and 5% caused difficulties due to concentrates sticking and freezing in chutes leading to the box car loaders. (Drying of concentrates is justified because of the high freight rate for the long shipping distance to the company owned smelter at Josephtown, Pa. near Pittsburgh.) It was long realized that installation of a thickener would permit the subsequent steps of concentrate handling to proceed more smoothly and would alleviate the problems existing in the filtering, drying, and loading operations. It was also realized that even a slightly lower filter cake moisture could mean considerable savings in fuel oil. However, all these factors were never quite sufficient to warrant the expense of a thickener until three more considerations were added to the picture. First, the advent of flocculants meant that a thickener of relatively small area could now be considered. Secondly, a complete renovation of the zinc flotation circuit was made between 1957 and 1961. The

Jan 1, 1967

Aamot, Olav Crone, (M'29) Chem. Engr., Elektrokemisk, Raadhusgt. 23, Oslo, Norway. Abadilla, Quirico A., (M'3S) Min. Engr., Dir., Bu¬ reau of Mines. Manila, P. I. Abbott, Agatin Townsend, (J'40) Jr. Engr., Phelps Dodge Corp., Morenci Branch, Morenci. Ariz. Abbott, Clarence E., (M'04) Civil Engr., V.P., Ten¬nessee Coal Iron & R.R.. Co., 1542 Brown -Marx Bldg.. Birmingham, Ala. Abel, Raymond L., (M'28) Chem. Engr., Command¬ing, Officer, Pittsburgh Chem. Warfare Procurement Dist., American Bank Bldg., Pittsburgh. Pa. Abel, Walter D., (M'32) Alin. Engr.. Div. of Cor¬porations, State of Calif., 403 California State Bldg., Los Angeles, Calif. Abele, Louis T., (M'31) 423 3rd Ave., Decatur, Ga. Abell, Leo M., (M'31) Mill Supt. & Met., Emperor Gold Min. Co., Led., Vatnkoula, Fiji Islands. Abernathy, G. E., (M'38) Geol., Kansas State Geol. Survey, Pittsburg, Bans. Abernathy, Jack H., (M'40) Peer. Engr., c/o Superior Oil Corp., National Bank of Tulsa Bldg., Tulsa, Okla. Aborn, Robert H., (M'10) Asst. Met., Research Lab., U. S. Steel Corp., Lincoln Highway, Kearny, N. J. Abraham, A. W., (M'39) Peer. Engr., Richfield Oil Corp., 555 S. Flower St., Los Angeles, Calif. Abramowitz, William L., (J'40) Chem., Industrial Inventions, Inc., 103 Foster Se., Peabody, Mass.

Jan 1, 1942

By W. A. Backofen, D. Lee

The deformation of textured sheet of titanium and several of its all-a (hcp) alloys was investigated with two kinds of experiments: tension testing along different directions in the plane of the sheet, and combined-stress loading along the principal axes of anisotropy (the rolling and transverse directions). Texture and plastic anisotropy were evaluated with pole figures and by measurement, as a function of orientation, of the tensile transverse-strain ratio, or R parameter. The results as a whole can be rationalized qualitatively with the present understanding of deformation mechanisms in titanium. Quantitative agreement between the orientation dependence of tensile yield strength and the Predictions of continuum ANISOTROPY in the properties of engineering materials is more the rule than the exception because anisotropy in structure is so common, and the one generally follows the other. Two broad categories of structural anisotropy are represented by mechanical fibering and crystallographic texture. The former is important in many aspects of fracture.' The latter has more significance for yielding and plastic deformation, theory, using the R measurements, was relatively poor. However, in tension-tension quadrants of the yield-locus diagrams, the difference between theory and experiment was hardly more than 10 pct. The maximum texture-hardening effect was found in a 4Al-1/4O2 alloy to be nearly 50 pct. In the compression-compression quadrant, {1012} deformation twinning prevented the locus from expanding much beyond the Position predicted for isotropic material. With increasing temperature the trend in R was downwards, approaching unity (isotropy) near the a-transus temperature; an accompanying development was large amounts of neck-free extension. which are of special concern in this paper. The tendency has been to view crystallographic texture more as a liability or curio than as an asset. The prominent exception is found in silicon-ferrite sheet for power-transformer cores, which is processed to develop a new optimum texture for high electrical efficiency. Yet it should be possible to find other examples, involving other kinds of properties. More specifically, there is good analytical reason to expect improved combined-stress yielding resistance in suitably textured material,2,3 and it has now been shown by experiment that texture hardening or softening is a potentially useful phenomenon in certain engineering devices and processes.'-I To date, work has included measurements of the transverse (width to thickness) strain ratios in the

Jan 1, 1967

By Sydney H. Ball

A QUARTER of a century ago, a pessimistic Belgian financier in conversation with the founder of the Belgian Congo, that great ruler, Leopold II, emphasized the danger to the colony should the synthesis of rubber be discovered. The king replied, "I do not worry. The Congo has had its ivory period; it now has its rubber period. Tomorrow it will have that of its mineral wealth; eventually that of agricultural products." That "tomorrow" arrived some twenty years ago. Through her mines the Belgian Congo has survived the present depression, and her mines for the next decade will safeguard her. The Congo, in turn. is the surest foundation industrially and financially of Belgium itself. In few, if any, political units is mining as dominant as in the Belgian Congo. In 1930, 1931 and 1932 mineral products represented respectively 67.9 per cent. 70.5 per cent and 59.3 per cent, of the total exports. In 1933 for each white person in the colony, there was produced about $1,675 worth of gold, diamonds, copper, tin ore and minor mineral products and in 1930 the per capita production, notwithstanding the larger population, was almost $2,000.

Jan 1, 1934

By George A. Grandy, D. W. Fuerstenau

Simulation of nonlinear grinding systems is discussed in the context of the size-discretized batch-grinding model. A linear approximation of environment-dependent (or nonlinear) selection functions is postulated for systems which exhibit feed grinding orders less than unity. For this, a convex linear combination of zero and first-order selection function forms is used to obtain an analytical solution that can be used for simulation. An example in which marked nonlinear behavior occurs is rod-mill grinding. Accordingly, a series of grinding experiments was carried out in a batch laboratory rod mill to test these techniques; agreement between experiment and the model was found to be very good. Recently, significant progress has been made in the simulation of linear grinding systems by using a population balance mathematical model. Herbst and Fuer-stenaul presented a parameter estimation scheme that can be used with the size-discretized batch-grinding model, and Gumtz and Fuerstenau3 have extended these techniques to the simulation of locked-cycle grinding. Grandy et aL." summarized the simulation of linear systems and noted important alternate solutions to the batch-grinding equation. Kelsall et a1.'-" discussed the dynamic simulation of linear batch grinding, as well as linear open and closed-circuit grinding. In all of these, the key word is linear, which certainly restricts the engineer trying to simulate a variety of grinding systems. This paper discusses an approach for the simulation of non-linear grinding systems, particularly those which exhibit grinding orders less than unity. Experimentally, dry rod-mill grinding is used to evaluate the technique presented. Batch Grinding Model The size-discretized batch-grinding model has been discussed in detail by Mika et al.'.' and by Herbst and Fuerstenau,' and therefore, will only be briefly developed here. The model is formulated by making a differential mass balance of each size fraction in such a manner that the equation parameters are precisely defined in terms of selection and breakage functions,' which can be either calculated'.' or estimated1 from experimental data. The model is phenomenological because it averages all stress-application events in the system and, therefore, does not distinguish the manner in which individual particles are stressed.' For this average environment, the resistance of all particles in a size fraction to breakage is defined by that size-frac-tion's selection function; and when fracture occurs from an average event, the breakage product size distribution is defined again by that size-fraction's breakage function. The model is deterministic and is derived in terms of a continuous time variable and a discretized size variable,' i.e., the n mass fractions associated with the n defined size intervals (see Table 1 for nomenclature).

Jan 1, 1971

By W. A. Rachinger, C. Graeme-Barber, R. L. Bell, R. C. Gifkins, T. G. Langdon

R. L. Bell. C. Graeme-Barber, and T. G. Langdon (Imperial College. London)— The internal-marker technique developed by Ishida, Mullendore, and Grant has enabled them to make some interesting observations on the role of grain boundary sliding in creep. Certain of their conclusions are supported by our own similar experiments on Magnox AL80 (Mg-0.8 pct Al) specimens containing several markers, full details of which will be published shortly. In particular, we would agree that: 1) Using the internal-marker method, there is little difference between Egb, the contribution made by grain boundary sliding to the total strain, measured at the surface and in the interior of a specimen. 2) The measurement of the change in grain shape during creep leads to an underestimation of the grain strain, and hence an overestimate of Egb.. However, the discrepancies between the values obtained by this method and those obtained using markers are not as great as Tables IV and V of Ishida, Mullendore, and Grant would suggest; see below. The authors' Eq. [I] which is used to compute Egb from the transverse displacement ITt of longitudinal marker lines is not given in the reference quoted,'' where in fact only relations for Egb in terms of the longitudinal displacements of markers were developed. As first pointed out by Gifkins and Gittins,12 a problem arises in the use of longitudinal markers. and we will show that Eq. [1] underestimates Egb in the interior by a factor of 2. In Fig. 12, two grains X and Y have become displaced by the vector AC which lies in the plane of the grain boundary ABCD separating them. A longitudinal marker has been split by this displacement into the two parts LA and CAW. If these were surface grains the transverse displacement, Ut. could be obtained by viewing normal to the "top" surface. If interior, a section through CD parallel to the top surface would show the same result, provided the longitudinal internal markers delineated planes normal to the top surface. (This is an essential feature of the markers not pointed out in the paper.) The important point is that the quantity Ut tan B (=BE=DF) only gives the elongation due to the one component AB of the sliding. The elongation V/tan 8 (=GD) due to the component AD must be added to produce the total elongation resulting from the boundary displacement AC. If the grain boundaries in a poly crystalline specimen are randomly oriented with respect to the stress axis it follows that In the interior of a specimen the two sums depend for any difference simply on the definitions "top'' and "side". On the surface it is possible that the two sums could differ somewhat. In either event it is clear that the authors' Eq. [I] underestimates Egb, and in the interior, and perhaps at the surface also, the appropriate formula is given by The suggested modification probably makes little difference to the comparison between surface and interior values of Egb where both were obtained from marker measurements. For the estimation of the correction becomes extremely important where the boundary contribution is large. In our own work on magnox, for example, we have obtained values of as large as 70 to 80 pct, under conditions of high temperature and low strain rate. The use of planar markers transverse to the stress axis would simplify the comparison between surface and interior behavior, because measurement of the longitudinal offsets Us of these markers could be summed to give the total elongation di-

Jan 1, 1965

By Jun Hino, P. G. Shewmon, P. A. Beck

THE investigations of Crussard,' of Guinier and Tennevin,' and of Dunn and Daniels," indicate that the subgrains formed in a cold worked and annealed metal are capable of growing at each other's expense during annealing, if the temperature of annealing is sufficiently high and the time is long enough. The results of Dunn and Daniels are particularly convincing in showing that subgrain growth is essentially the result of the free surface energy associated with the subboundaries. In subgrain growth, as in ordinary grain growth, energy is gained as a result of the decrease in total subboundary surface area per unit volume. Recently, Wood and Scrutton4 found that the rate of subgrain growth upon annealing increased very considerably, if simultaneously a creep strain was applied to the specimen at a low strain rate. Working with 99.98 pct pure fine-grained aluminum, these investigators found that the continuous X-ray diffraction back-reflection rings of material strained at room temperature remained continuous after heating for ten days at 250 °C. However, when heated at the same temperature under a stress of 1000 psi even for only three days, the formerly continuous X-ray diffraction rings broke up into numerous dots, which were fairly clearly separated from each other. The continuous X-ray diffraction rings were interpreted as indications of a very small subgrain size, not resolved by the X-ray diffraction method used. The breaking up of the continuous X-ray diffraction ring during annealing under stress was taken as an indication of a great increase in subgrain size, so that the individual subgrains could then be resolved. The effect of simultaneous strain at a low strain rate in accelerating subgrain growth, discovered by Wood and Scrutton and designated by them as "cell growth," is of fundamental importance. The experiments described in this note were carried out in order to confirm Wood and Scrutton's results by direct metallographic observation. Also, information was sought as to the minimum creep strain necessary to produce this effect. A fine grained high purity aluminum strip was prepared by alternate 33 pct rolling and annealing treatments for 1 hr at 350°C. Specimens cut from this strip were subjected to a relatively fast creep strain of 7.2 pct in 3.5 min at 300°C under a constant load initially corresponding to 1185 psi. The subgrains set up were large enough (about 0.015 to 0.03 mm) to be clearly observed (Fig. 1) at X200 magnification with polarized light, after electrolytic polishing and anodic etching, producing a fine oxide film." The corresponding X-ray diffraction pattern is shown in Fig. la. After the fast creep strain treatment a portion of the specimen was subjected to a creep strain of 8.3 pct in 44 hr at 350°C under a constant load initially corresponding to 320 psi. Another portion, annealed under the same conditions, but not strained, served as control specimen. The subgrain size of a typical area of the specimen annealed under strain and of the one annealed without strain is shown in Figs. 2 and 3 (X-ray diffraction patterns, Figs. 2a and 3a). Annealing without strain produced clearly observable subgrain growth (subgrain size: about 0.03 to 0.05 mm). The effect of simultaneous strain was to increase greatly the rate of subgrain growth (resulting in a subgrain size of approximately 0.05 to 0.13 mm), in accordance with Wood and Scrutton. In another experiment, the effect of the amount of simultaneous strain was studied. The initial subgrain structure was set up by fast creep, as described previously. The specimen was then heated at 350 °C under a constant load initially corresponding to 320 psi, as above, for 2.2 hr (0.24 pct strain), and 8.8 hr (0.58 pct strain). Comparison with the corresponding unstrained control specimens by means of X-ray diffraction showed that 0.58 pct strain definitely had an effect, but the effect of 0.24 pct strain was doubtful.

Jan 1, 1953

By E. I. Larsen, E. F. Swazy, F. R. Hensel

High strength, high-conductivity copper-base alloys have found considerable use in the resistance welding and electrical industry in the form of castings, forgings, or wrought products. There are a number of parts utilized by these industries which would lend themselves to manufacture by powder metallurgical methods provided the required physical and electrical properties are obtainable with such methods. The present paper describes the results of a study of certain copper-base powder metallurgical products susceptible to precipitation hardening. Copper Powders The general types of commercially available copper powders are flake, spherical and electrolytic. Micrographs of these three types are shown in Figs. I, 2 and 3. The difference in particle shape is pronounced and obvious. The type of powder used is determined, or at least indicated, by the final properties desired in the finished article. The type of powder employed during the present investigation was electrolytic powder shown in Fig. 3, and was chosen because of its particular adaptability to the work described in this Paper. The screen and chemical analyses of this powder are shown in Table I. In the preparation of compacts of high electrical conductivity, the purity of the copper powder is of importance in addition to other factors, such as density and the state of internal stresses. These variables were studied briefly by pressing a number of compacts to various pressed densities, sintering them for one hour in hydrogen at 975OC and repressing. The size of the finished compacts was 1/4, by % by 8 in. The time interval from the application to the termination of pressure was approximately 20 sec. Some of the compacts were annealed before testing. The results are listed in Figs. 4 to 8, inclusive. In Fig. 4 the curves of pressed density vs. compacting pressure, and sintered density versus compacting pressure show the typical direct relationship of pressure and density. Compacting pressures exceeding about 30 tons per sq. in. result fiequently in expansion during sintering for the type of powder used. Fig. 5 indicates that variations in the initial pressed density within the range of about 5 to 6 grams per c, c., affect only slightly the pressure required to obtain a

Jan 1, 1946

By E. I. Larsen, E. F. Swazy, F. R. Hensel

High strength, high-conductivity copper-base alloys have found considerable use in the resistance welding and electrical industry in the form of castings, forgings, or wrought products. There are a number of parts utilized by these industries which would lend themselves to manufacture by powder metallurgical methods provided the required physical and electrical properties are obtainable with such methods. The present paper describes the results of a study of certain copper-base powder metallurgical products susceptible to precipitation hardening. Copper Powders The general types of commercially available copper powders are flake, spherical and electrolytic. Micrographs of these three types are shown in Figs. I, 2 and 3. The difference in particle shape is pronounced and obvious. The type of powder used is determined, or at least indicated, by the final properties desired in the finished article. The type of powder employed during the present investigation was electrolytic powder shown in Fig. 3, and was chosen because of its particular adaptability to the work described in this Paper. The screen and chemical analyses of this powder are shown in Table I. In the preparation of compacts of high electrical conductivity, the purity of the copper powder is of importance in addition to other factors, such as density and the state of internal stresses. These variables were studied briefly by pressing a number of compacts to various pressed densities, sintering them for one hour in hydrogen at 975OC and repressing. The size of the finished compacts was 1/4, by % by 8 in. The time interval from the application to the termination of pressure was approximately 20 sec. Some of the compacts were annealed before testing. The results are listed in Figs. 4 to 8, inclusive. In Fig. 4 the curves of pressed density vs. compacting pressure, and sintered density versus compacting pressure show the typical direct relationship of pressure and density. Compacting pressures exceeding about 30 tons per sq. in. result fiequently in expansion during sintering for the type of powder used. Fig. 5 indicates that variations in the initial pressed density within the range of about 5 to 6 grams per c, c., affect only slightly the pressure required to obtain a

Jan 1, 1946